Projected Difference Mapping on Workpieces for Faster Manual Rework
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Solution Overview
Problem
Workers in existing work support systems need to divert their attention from the workpiece to check displays for work details, and on flat or simple-shaped workpieces, it's difficult to identify corresponding work areas, leading to increased time in determining work requirements.
Innovation Solution
A system comprising a measurement apparatus, a projector, and an arithmetic apparatus that measures and projects a difference map directly onto the workpiece, allowing workers to see where adjustments are needed without looking away, using a projector to overlay a picture of the difference map on the workpiece surface at corresponding measurement points.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If the worker checks the display to determine work details, then the worker can obtain information about the workpiece shape difference, but the worker must take eyes off the workpiece which increases the time required
Solution Approach 1:
The patent introduces a display device as an intermediary that presents work difference information in a format that does not require the worker to shift attention away from the workpiece. The display shows a visual representation of the workpiece with highlighted portions indicating where work is needed, allowing the worker to obtain information without breaking visual contact with the actual workpiece.
2Ease of manufacture
If the workpiece has a flat-plate shape with few characteristic portions, then the workpiece is simpler to manufacture, but the worker cannot understand which displayed portion corresponds to which actual workpiece portion
Solution Approach 1:
The patent applies color coding to different portions of the workpiece display to enhance identification. Different colors or shading patterns are used to represent different work differences or work priorities, allowing the worker to quickly identify which portions of the workpiece need attention even when the workpiece lacks distinctive geometric features.
Solution Approach 2:
The patent divides the workpiece display into multiple segmented portions or regions, each corresponding to a specific area of the actual workpiece. This segmentation allows the worker to systematically identify and locate work areas on the workpiece by matching the segmented display regions with the corresponding physical areas.
3Loss of information
If the worker must match displayed workpiece portions with actual workpiece portions, then the worker can determine work locations, but this matching process increases the time required
Solution Approach 1:
The patent creates a visual copy or representation of the workpiece on the display that maintains the same spatial relationships and proportions as the actual workpiece. This accurate copying allows the worker to directly map displayed portions to actual workpiece portions without time-consuming mental transformation or measurement, as the display serves as a true-to-scale reference.
Data Source
AI summary
A work support system includes a measurement apparatus measuring a state of each of multiple measurement points on an object surface of a workpiece, a projector apparatus, and an arithmetic apparatus creating a projection image of the projector apparatus based on a measurement result of the measurement apparatus. The arithmetic apparatus calculates a difference between a state measured by the measurement apparatus and a target state for each of the multiple measurement points, and creates the projection image such that a picture of a characteristic point representative of the difference at each of the multiple measurement points is projected by the projector apparatus at a position of a corresponding measurement point on the object surface of the workpiece.